Recreating the Dallas Cowboys’ Red Kettle with 425 Manufacturing
A community-driven partnership combining advanced manufacturing and local commitment to support The Salvation Army’s holiday fundraising.
We have partnered with 425 Manufacturing to bring the Dallas Cowboys’ iconic Red Kettle to life in support of a meaningful cause
ROCKFORD, Illinois — We are proud to collaborate with 425 Manufacturing in support of The Salvation Army, helping recreate the Dallas Cowboys’ iconic Red Kettle for this year’s holiday fundraising campaign.
A Partnership for a Purpose
This initiative was led by Micheal Thomason, President of 425 Manufacturing, who invited us to join the project and contribute our advanced manufacturing expertise to this important community effort.
As part of the collaboration, we provided our additive manufacturing capabilities to 3D-print the oversized kettle using carbon fiber and a heavy-duty polymer. The structure weighs more than 225 pounds, stands nearly 4 feet tall, and spans almost 6 feet in width.
The production process required more than 12 hours of continuous manufacturing, followed by a meticulous finishing phase. Once completed, 425 Manufacturing applied the bright red coating that gives the kettle its iconic and recognizable appearance.
Technology Highlights
Advanced Multi-Axis Additive Manufacturing: We leveraged our multi-axis 3D printing capabilities to produce the kettle, enabling the creation of complex curved geometries and larger overhangs compared to traditional additive systems. Our tilting extruder allowed seamless material deposition across the kettle’s rounded surfaces.
AI-Driven Slicing: We used AiBuild’s AI-powered software to slice the part, optimizing toolpaths, material flow, and overall print integrity—key factors for achieving reliability in large-scale additive manufacturing.
At Ingersoll, we are honored to support initiatives that strengthen our community. This project allowed us to put our technology and engineering capabilities at the service of a meaningful cause. Working alongside local partners and contributing to their efforts and initiative on something that positively impacts people’s lives is really important, and what we deeply value
Jason Melcher
Vice President and Sales Director of Composite and Additive Technology at Ingersoll Machine Tools
Technology in Service of the Community
The new Red Kettle made its debut at the Stroll on State celebration in Rockford on Saturday, November 29, 2025. With this installation, we demonstrated how local businesses and community organizations can come together to support charitable initiatives and inspire new opportunities for holiday giving.
Source: https://www.mystateline.com/news/rockford-salvation-army-local-businesses-recreate-dallas-cowboys-red-kettle/
